laminar flow heat transfer enhancement...
TRANSCRIPT
LAMINAR FLOW HEAT TRANSFER ENHANCEMENT IN MULTY-START
SPIRALLY CORRUGATED TUBES
ZAID SATTAR KAREEM
A thesis submitted in fulfilment of the
requirements for the award of the degree of
Doctor of Engineering (Mechanical Engineering)
Faculty of Mechanical Engineering
Universiti Teknologi Malaysia
AUGUST 2016
iii
ACKNOWLEDGEMENT
Foremost, I say “Alhamdulillah” for the first of godsends and providing me the
strength, patience, courage, and determination in completing this work. All graces and
thanks belong to Almighty Allah Subhanahu Wa-Ta'ala (S.W.T) and May blessings and
peace be upon our prophet Mohammad (S.A.A.W).
Many thanks and Gratitude goes to my supervisor Assoc. Prof. Dr. Tholudin Mat
Lazim, and to my co-supervisors Prof. Dr. Mohd Nazri Mohd Jaafar and Prof. Dr. Ir.
Shahrir Abdullah for their incredible guidance. The successful completion of this work
is due to the support of the supervision members.
I am also indebted to Universiti Teknologi Malaysia (UTM) for their help and
care. The appreciation should forward to University Kebangsaan Malaysia, NGVD
center for allowing me to use their resources.
My fellow postgraduate students should also be recognized for their support. My
sincere appreciation also extends to all my colleagues and others who have provided
assistance at various occasions. Their views and tips are useful indeed. Unfortunately, it
is not possible to list all of them in this limited space. I am grateful to all my family
members.
iv
ABSTRACT
Heat transfer plays an important role in many aspects of human life, especially
the forced convection type. Hence, it has become very important to invest resources and
efforts in this vital field to make some difference. Recently, the trend of using compact
heat transport devices is of great interest to obtain an efficient, low cost and small size
product which requires less production time with fewer efforts. Employing of artificial
roughness, such as corrugation, for heat transfer enhancement in heat exchanger and
other industrial thermal devices have shown promising results, with good performance
reliability at lower cost. Therefore, the current study aimed to investigate experimentally
and numerically the heat transfer enhancement and pressure drop increase in tubes with
a superior type of corrugation i.e. the spiral corrugation. The flow of ionised water as
working fluid in tubes at low Reynolds number was constructed to investigate the
laminar flow regime of 100≤ Re≤1300. Five spirally corrugated tubes and one smooth
tube under constant wall heat flux boundary condition with various thermo-physical
properties was investigated through experimental test and computational fluid dynamics
simulation. Different corrugation parameters, such as corrugation height to diameter and
corrugation pitch to diameter ratios were studied in different corrugated tube sizes. The
results showed that the severity index, which combines the effect of both corrugation
height and pitch, has great effects on heat transfer rate, friction factor, and thermal
performance of the flow inside spirally corrugated tubes. The heat transfer enhancement
was in the range of 1.3-2 compared to a smooth tube, accompanied with an increase in
friction factor in the range 1.1-1.9. The thermal performance range was found to be
improved by 1.2-2.08 times. The heat transfer and friction factor correlation are
proposed.
v
ABSTRAK
Pemindahan haba memainkan peranan penting dalam banyak aspek kehidupan
manusia, terutamanya jenis pemindahan haba olakan paksa. Oleh itu, menjadi sangat penting
untuk melabur dalam sumber dan tenaga usaha dalam bidang yang amat perlu ini untuk
menghasilkan sesuatu perubahan yang ketara. Kebelakangan ini, penggunaan alat
pengangkutan haba yang padat telah menjadi satu polar yang sangat menarik untuk
meningkatkan kecekapan, menurunkan kos dan saiz produk sehingga boleh mengurangkan
masa pengeluaran dan daya usaha. Penggunaan kekasaran tiruan, seperti permukaan kerut-
beralun, untuk peningkatan pemindahan haba dalam penukar haba dan lain-lain peranti terma
skala industri telah menampakkan kejayaan, dengan prestasi kebolehpercayaan yang baik dan
kos yang lebih efektif. Oleh itu, kajian ini bertujuan untuk menyiasat melalui kaedah ujikaji
dan berangka, peningkatan pemindahan haba dan pertambahan penurunan tekanan dalam tiub
yang mempunyai kerut-beralun yang lebih unggul iaitu kerut-beralun pilin. Aliran air terion
sebagai bendalir bekerja dalam tiub pada nombor Reynolds yang rendah telah dibina untuk
menyiasat rejim aliran lamina yang mempunyai 100≤ Re≤1300. Lima tiub kerut-beralun pilin
dan satu tiub licin di bawah keadaan sempadan fluks haba dinding pemalar dengan pelbagai
sifat terma fizik disiasat melalui ujian ujikaji dan simulasi perkomputeran dinamik bendalir.
Berbagai parameter kerut-beralun, seperti nisbah ketinggian kerut-beralun kepada garis pusat
dan nisbah jarak alun kepada garis pusat dikaji dalam berbagai saiz tiub kerut-beralun. Hasil
kajian menunjukkan bahawa indeks keamatan, yang menggabungkan kesan kedua-dua
ketinggian kerut-beralun dan jarak alun, mempunyai kesan yang besar pada kadar
pemindahan haba, faktor geseran, dan prestasi terma untuk aliran di dalam tiub kerut-beralun
pilin. Peningkatan pemindahan haba adalah dalam julat 1.3-2 berbanding dengan tiub licin,
dengan penambahan dalam faktor geseran dalam julat 1.1-1.9. Julat prestasi terma telah dapat
diperbaiki sebanyak 1.2-1.9 kali ganda. Sekaitan pemindahan haba dan sekaitan faktor
geseran telah dicadangkan.
vi
TABLE OF CONTENTS
CHAPTER TITLE PAGE
DECLARATION ii
ACKNOWLEDGEMENT iii
ABSTRACT iv
ABSTRAK v
TABLE OF CONTENTS vi
LIST OF TABLES x
LIST OF FIGURES xi
LIST OF ABBREVIATIONS xvii
LIST OF SYMBOLS xviii
LIST OF APPENDICES xx
1 INTRODUCTION 1
1.1 Problem background 1
1.2 Problem statement 5
1.3 Research hypothesis 6
1.4 Research questions 6
1.5 Objectives 7
1.6 Scope of research 8
1.7 Significance and contributions of this study 8
1.8 Organization of the thesis 9
vii
2 LITERATURE REVIEW 11
2.1 Introduction 11
2.2 Active method 12
2.3 Passive methods 14
2.3.1 Twisted tape 15
2.3.2 Coiled wires 17
2.3.3 Swirl generators 19
2.3.4 Conical ring 21
2.3.5 Ribs 22
2.3.6 Dimples 23
2.3.7 Grooves 25
2.3.8 Additives (nanofluid) 27
2.3.9 Miscellaneous techniques 29
2.3.10 Corrugations 30
2.3.11 Experimental studies on corrugation 31
2.3.11.1 Laminar flow 31
2.3.11.2 Turbulent flow 36
2.3.11.3 Laminar to turbulent 50
2.3.12 Numerical studies on corrugation 56
2.3.12.1 Laminar flow 56
2.3.12.2 Turbulent flow 58
2.3.12.3 Laminar to turbulent 62
2.3.13 Miscellaneous corrugation studies 62
2.4 Summary 63
3 EXPERIMENTAL METHODOLOGY 65
3.1 Introduction 65
3.2 Characteristics of spirally corrugated tubes 66
3.3 Corrugation height and pitch 69
3.4 Heat transfer and pressure losses measurement 70
3.4.1 Experimental set up 70
viii
3.4.2 Experimental procedures 74
3.4.3 The determination of heat transfer and friction
factor 75
3.5 Calibration of the instruments 77
3.5.1 Calibration of thermocouples 78
3.5.2 Calibration of pressure transducers 79
3.5.3 Calibration of water flow meters 80
4 MATHEMATICAL MODELLING 82
4.1 Introduction 82
4.2 Numerical modelling 82
4.2.1 Geometry of simulated tubes 83
4.2.2 Governing equations 87
4.2.2.1 Continuity and momentum equations 87
4.2.2.2 Energy equation 88
4.3 Meshing Strategy 88
4.2.3 Mesh quality 89
4.2.4 Grid density 90
4.4 Boundary conditions and assumptions 93
4.5 Heat transfer determination 93
4.6 CFD Verification 95
4.6.1 Solution algorithm 95
4.6.2 Solution algorithm and solution method 96
4.6.3 Residual convergence 96
4.6.4 Grid convergence index 98
4.7 CFD Validations 104
4.7.1 Heat transfer validation 105
4.7.2 Friction factor validation 106
4.9 Summary 108
ix
5 RESULTS AND DISCUSSION 110
5.1 Introduction 110
5.2 Effect of corrugation profile on heat transfer 110
5.3 Friction factor results 134
5.4 Effect of corrugation height on heat transfer 139
5.5 The effect of corrugation pitch on heat transfer 144
5.6 Number of start effect on heat transfer 146
5.7 The effect of severity index on heat transfer 148
5.8 Effect of number of start on temperature 152
5.9 Effect of number of start on pressure drop 154
5.10 Effect of number of start on flow pattern 157
5.11 Nusselt Number and friction factor enhancement
Ratios 163
5.12 Thermal performance factor 169
5.13 Correlations 173
5.13.1 Nusselt number correlation 173
5.13.2 Friction factor correlation 175
6 CONCLUSIONS AND RECOMMENDATION 178
6.1 Conclusions 178
6.2 Recommendations for further study 180
6.3 Main contributions 181
REFERENCES 183
Appendix A-C 201-214
x
LIST OF TABLES
TABLE NO. TITLE PAGE
2.1 Summary of experimental studies concerned with corrugation
for laminar flow 32
2.2 Summary of experimental studies concerned with corrugation
for turbulent flow 36
2.3 Summary of experimental studies concerned with corrugation
for laminar-turbulent flow 51
2.4 Summary of numerical and analytical studies concerned with
corrugation for laminar flow 56
2.5 Summary of numerical and analytical studies concerned with
corrugation for turbulent flow 58
3.1 Tubes characteristics for number of start N=3 67
3.2 The accuracy of instruments and sensors 77
4.1 Characteristics of simulated tubes 83
4.2 GCIs of the case N=2, Re=100 and φ=0.631×10-3
104
5.1 Constant values of A and B of eq. (5.6) 173
5.2 Constant values m and n of eq. (5.8) 176
xi
LIST OF FIGURES
FIGURE NO. TITLE PAGE
1.1 Publications regarding the corrugation in heat transfer
enhancement 4
3.1 Spirally corrugated tubes configurations 66
3.2 Corrugated tube characteristics 68
3.3 The schematic diagram of experimental set up 71
3.4 The experimental rig 72
3.5 Thermocouples arrangement on the test pipe 73
3.6 Thermocouples holes 73
3.7 Calibration of thermocouples 79
3.8 Calibration of pressure transducer 80
4.1 Two-start geometry of the numerical model 85
4.2 Three-start geometry of the experimental and numerical
model 85
4.3 Four-start geometry of the numerical model 86
4.4 Five-start geometry of the numerical model 86
4.5 Mesh model of the two-start tube 91
4.6 Mesh model of the three-start tube 92
4.7 Mesh model of the four-start tube 92
4.8 Mesh model of the five-start tube 92
4.9 Residual convergence 97
4.10 Comparison of the measured and numerical Nusselt num-
ber of water with the Shah equation 105
xii
4.11 Comparison of the measured and numerical friction fac-
tor with those determined by equation 4.27 107
5.1 Numerical Nusselt number numerical data along the tube for
N=2, Re=100 112
5.2 Numerical Nusselt number numerical data along the tube for
N=2, Re=400 112
5.3 Numerical Nusselt number numerical data along the tube for
N=2, Re=700 113
5.4 Numerical Nusselt number numerical data along the tube for
N=2, Re=1000 113
5.5 Numerical Nusselt number numerical data along the tube for
N=2, Re=1300 114
5.6 Nusselt number comparison of numerical and experimental
data along the tube for N=3, Re=100 115
5.7 Nusselt number comparison of numerical and experimental
data along the tube for N=3, Re=400 115
5.8 Nusselt number comparison of numerical and experimental
data along the tube for N=3, Re=700 116
5.9 Nusselt number comparison of numerical and experimental
data along the tube for N=3, Re=1000 116
5.10 Nusselt number comparison of numerical and experimental
data along the tube for N=3, Re=1300 117
5.11 Numerical Nusselt number numerical data along the tube for
N=4, Re=100 118
5.12 Numerical Nusselt number numerical data along the tube for
N=4, Re=400 118
5.13 Numerical Nusselt number numerical data along the tube for
N=4, Re=700 119
5.14 Numerical Nusselt number numerical data along the tube for
N=4, Re=1000 119
5.15 Numerical Nusselt number numerical data along the tube for
N=4, Re=1300 120
5.16 Numerical Nusselt number numerical data along the tube for
N=5, Re=100 120
5.17 Numerical Nusselt number numerical data along the tube for
N=5, Re=400 121
5.18 Numerical Nusselt number numerical data along the tube for
N=5, Re=700 121
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5.19 Numerical Nusselt number numerical data along the tube for
N=5, Re=1000 122
5.20 Numerical Nusselt number numerical data along the tube for
N=5, Re=1300 122
5.21 Average Nusselt number versus Reynolds number for N=2 124
5.22 Average Nusselt number versus Reynolds number for N=3 124
5.23 Average Nusselt number versus Reynolds number for N=4 125
5.24 Average Nusselt number versus Reynolds number for N=5 125
5.25 Heat transfer rate versus Reynolds number for N=2 126
5.26 Heat transfer rate versus Reynolds number for N=3 127
5.27 Heat transfer rate versus Reynolds number for N=4 127
5.28 Heat transfer rate versus Reynolds number for N=5 128
5.29 Average Nusselt number versus Reynolds number for
φ=0.631×10-3
129
5.30 Average Nusselt number versus Reynolds number for
φ=890.0×10-3
129
5.31 Average Nusselt number versus Reynolds number for
φ=29011×10-3
130
5.32 Average Nusselt number versus Reynolds number for
φ=19500×10-3
130
5.33 Average Nusselt number versus Reynolds number for
φ=3.857×10-3
131
5.34 Average Nusselt number versus Severity index for N=2 132
5.35 Average Nusselt number versus Severity index for N=3 132
5.36 Average Nusselt number versus Severity index for N=4 133
5.37 Average Nusselt number versus Severity index for N=5 133
5.38 Friction factor versus Reynolds number for N=2 135
5.39 Friction factor comparison of numerical and experimental
results at N=3 and for different values of severity index 135
5.40 Friction factor versus Reynolds number for N=4 136
5.41 Friction factor versus Reynolds number for N=5 136
5.42 Friction factor versus Severity index for N=2 137
5.43 Friction factor versus Severity index for N=3 138
5.44 Friction factor versus Severity index for N=4 138
xiv
5.45 Friction factor versus Severity index for N=5 139
5.46 Temperature contour of Tube no. 6 of φ = 0.631×10-3
140
5.47 Temperature contour of Tube no. 7 of φ = 0.898×10-3
140
5.48 Temperature contour of Tube no. 8 of φ = 1.822×10-3
141
5.49 Temperature contour of Tube no. 9 of φ = 2.588×10-3
141
5.50 Temperature contour and vector of Tube no. 10 of
φ = 3.857×10-3
142
5.51 Velocity field of Tube no. 9 of φ = 2.588×10-3
143
5.52 Vorticity magnitude contour of Tube no. 6 of φ = 0.631×10-3
144
5.53 Streamline of Tube no. 8 of φ = 1.822×10-3
145
5.54 Pressure field of Tube no. 4 of φ = 2.588×10-3
146
5.55 Pressure field of Tube no. 9 of φ = 2.588×10-3
147
5.56 Pressure field of Tube no. 14 of φ = 2.588×10-3
147
5.57 Pressure field of Tube no. 19 of φ = 2.588×10-3
148
5.58 Velocity vector (coloured by temperature values) of
Tube no. 10, with φ=3.857×10-3
149
5.59 Velocity vector (coloured by temperature values) of
Tube no. 9, with φ=2.588×10-3
149
5.60 Velocity vector (coloured by temperature values) of
Tube no. 8, with φ=1.822×10-3
150
5.61 Velocity vector (coloured by temperature values) of
Tube no. 7, with φ=0.898×10-3
150
5.62 Velocity vector (coloured by temperature values) of
Tube no. 6, with φ=0.631×10-3
151
5.63 Temperature contour of N=2 152
5.64 Temperature contour of N=3 153
5.65 Temperature contour of N=4 153
5.66 Temperature contour of N=5 154
5.67 Pressure contour of N=2 155
5.68 Pressure contour of N=3 155
5.69 Pressure contour of N=4 156
5.70 Pressure contour of N=5 156
5.71 Velocity vector of N=2 157
xv
5.72 Velocity vector of N=3 158
5.73 Velocity vector of N=4 158
5.74 Velocity vector of N=5 159
5.75 Vorticity magnitude of N=2 159
5.76 Vorticity magnitude of N=3 160
5.77 Vorticity magnitude of N=4 160
5.78 Vorticity magnitude of N=5 161
5.79 Velocity contour of N=2 161
5.80 Velocity contour of N=3 162
5.81 Velocity contour of N=4 162
5.82 Velocity contour of N=5 163
5.83 Friction factor enhancement ratios versus Reynolds number
for different severity index for N=2 164
5.84 Friction factor enhancement ratios versus Reynolds number
for different severity index for N=3 165
5.85 Friction factor enhancement ratios versus Reynolds number
for different severity index for N=4 165
5.86 Friction factor enhancement ratios versus Reynolds number
for different severity index for N=5 166
5.87 Nusselt number enhancement ratios versus Reynolds number
for different severity index for N=2 167
5.88 Nusselt number enhancement ratios versus Reynolds number
for different severity index for N=3 167
5.89 Nusselt number enhancement ratios versus Reynolds number
for different severity index for N=4 168
5.90 Nusselt number enhancement ratios versus Reynolds number
for different severity index for N=5 168
5.91 Thermal performance factor versus Reynolds number of N=2
and for different severity index 170
5.92 Thermal performance factor versus Reynolds number of N=3
and for different severity index 170
5.93 Thermal performance factor versus Reynolds number of N=4
and for different severity index 171
5.94 Thermal performance factor versus Reynolds number of N=5
and for different severity index 171
xvi
5.95 The comparison of the Nusselt number with the Nusselt
number correlation 5.6 175
5.96 The comparison of the Friction factor with the Friction factor
correlation 5.8 177
xvii
LIST OF ABBREVIATIONS
C/W - Twisted tape clearance ratios
CFD - Computational fluid dynamics
CITSG - Conical injector type swirl generator
CR - Conical-ring
DDIR - Discrete double incline ribs
DR - Divergent ring
DWs - Delta-winglet type vortex generator
e/D - Heat capacity of the fluid, kJ/kg oC
FEM - Finite element method
FVM - Finite volume method
Fw - Wave factor
MF - Mass flux
OHP - Oscillating heat pipe
p/D - Diameter of the tube, m
PCR - Perforated conical-ring
PR - Pitch ratio
TET - Twisted elliptical tube
TT - Twisted tape
WVG - Winglet type vortex generator
Y/W - Twisted tape twist ratios
xviii
LIST OF SYMBOLS
A - Surface area, m2
Cp - Heat capacity of the fluid, kJ/kg oC
D - Diameter of the tube, m
e - Corrugation height
Gz - Graetz number
L - Length of the tube, m
k - Thermal conductivity, W/m·K
H - Heat transfer coefficient, W/m2·K
N - Number of start riding
Nu - Nusselt number
P - Pressure, Pascal
p - Corrugation Pitch
Pr - Prandtl number
Pe - Peclet number
Re - Reynold number
T - Temperature, K
t - Time, s
u - Velocity, m/s
q - Heat flux at the wall, W/m2
xix
GREEK LETTER
µ - Dynamic viscosity of the fluid, kg·m/s2
ρ - Density of the material, kg/m3
η - Thermal efficiency
φ - Severity Index
SUBSCRIPT SCRIPT
B - Bulk
b - Bore
en - Envelope
n - Nominal
x - Local
xx
LIST OF APPENDICES
APPENDIX TITLE PAGE
A Result of numerical local Nusselt number 201
B Result of numerical friction factor 212
C Experimental uncertainties 214
1
CHAPTER 1
INTRODUCTION
1.1. Problem Background
Heat transfer is the exchange of thermal energy between physical systems,
depending on the temperature, by dissipating heat. The fundamental modes of heat
transfer are conduction, convection and radiation.
Heat transfer always occurs from a region of high temperature to another
region of lower temperature. Heat transfer changes the internal energy of both
systems involved according to the First Law of Thermodynamics.
The flow of fluid may be forced by external processes, or sometimes (in
gravitational fields) by buoyancy forces caused when thermal energy expands the
fluid (for example in a fire plume), thus influencing its own transfer. The latter
process is often called "natural convection". All convective processes also move heat
partly by diffusion, as well. Another form of convection is forced convection. In this
case the fluid is forced to flow by use of a pump, fan or other mechanical means.
2
Convective heat transfer, or convection, is the transfer of heat from one place
to another by the movement of fluids, a process that is essentially the transfer of heat
via mass transfer. Bulk motion of fluid enhances heat transfer in many physical
situations, such as (for example) between a solid surface and the fluid. Convection is
usually the dominant form of heat transfer in liquids and gases. Although sometimes
discussed as a third method of heat transfer, convection is usually used to describe
the combined effects of heat conduction within the fluid (diffusion) and heat
transference by bulk fluid flow streaming.
The heat transfer is a very interesting field for economical, functional and
environmental reasons; it is almost related to each aspect of human lives. Therefore,
the enhancement of such field is quite essential, especially the forced convective heat
transfer field. The conversion and utilization of energy in industrial, commercial, and
domestic applications involve heat exchange processes. Some common examples are
steam generation and condensation in power and cogeneration plants; sensible
heating and cooling of viscous media in thermal processing of chemical,
pharmaceutical, and agricultural products, refrigerant evaporation and condensation
in air conditioning and refrigeration system, gas flow heating in manufacturing and
waste-heat recovery; air and liquid cooling of engine and turbo-machinery systems,
and cooling of electrical machines and electronic devices. Improved heat exchange,
over and above that in the usual or standard practice, can significantly improve the
thermal efficiency in such applications as well as the economics of their design and
operation
The engineering cognizance of the need to increase the thermal performance
of heat exchangers, thereby effecting energy, material and cost savings as well as
mitigation of environmental degradation had led to the development and use of many
heat transfer enhancement techniques. These methods have in the past been referred
to variously as augmentation and intensification. One of the popular ways to enhance
heat transfer which is recently of interests is using artificial surface roughness, ribs,
grooves and corrugations. Spirally corrugated surface hold the promise of enhancing
3
the heat transfer in tubes and, they are one of the most cost-effective enhancement
methods.
Basically, there are two different methods to increase the rate of heat
transferred and both of them are based on an enhanced heat transfer surface
geometry to provide a higher thermal performance. One is the active method and the
other is the passive method. The active technique requires external forces and the
passive technique requires special surface geometries or fluid additives. The
motivation behind this activity includes the desire to produce more effective heat
exchangers and heat transfer enhancement in many other industrial applications. The
ultimate objectives being to provide energy, material, and economic savings for the
users of enhanced heat transfer technology.
Setting up a periodic disturbance along the streamwise is a favorable way to
enhance the heat transfer in forced convection due to its simplicity and effectiveness
as Adachi and Uehara reported [1]. This kind of periodical retardation plays a vital
rule in the enhancement process by breaking the thermal boundary layer and distorts
the temperature field of the fluid flowing inside the tube; hence it will minimize the
resistance or the reluctance to the heat transfer. This mechanism is widely mentioned
and cited by researches as it clearly described and reviewed in Chapter 2.
Corrugation helps on increases heat transfer enhancement due to the presence
of secondary movements of the fluid adjacent to the wall. Unfortunately, in spite of
the importance of the corrugation in various industrial applications, there is not
enough publications concerning the corrugation employment in heat transfer
enhancement. Only recently, the employing of corrugation for the enhancement of
heat transfer has become interesting because it has the combined merits of extended
surfaces, turbulators and roughness as shown in Figure 1.1.
4
Figure 1.1 Publications regarding the corrugation in heat transfer enhancement [1]
Therefore, the emphasis was given in this investigation research to the use of
the spiral corrugation in heat transfer enhancement.
In the last few years, the attention was given to the importance of using
corrugation in the heat transfer enhancement due to the mentioned merits. In
addition, the main functions of corrugation are to promote the secondary
recirculation flow by inducing radial velocity components, mixing the flow layers
and finally, increasing the wet perimeter with holding the throat cross-section area
constant.
There is enough number of investigators whom tried to study the heat transfer
enhancement in both ways, experimentally and numerically. A different corrugation
profiles and arrangement were employed. Many fluids were tested inside various
tube arrangements. But yet, the studies concerning the employing of both
experimental and numerical techniques for the determination of thermal performance
5
of spirally corrugated tubes for the flow of water at low Reynolds number are limited
in spite of the thrust for a smaller size, cost effective thermal transport devices [2]. In
addition, the traditional corrugation profile was also used over and over, and the
creativity regarding the corrugation profile and its effect was completely neglected.
1.2. Problem Statement
As it is commonly known, energy resources is exhausting at a tremendous
rate; hence, it has become important to improve the heat transfer characteristics of
tubes in view of the energy situation and to avoid the issues of imminent energy lack
with suitable and well functional precautions. The passive heat transfer enhancement
basically based on the adopting of many tools that induces a swirl and vorticities at
the secondary flow region, which mixed the fluid layers and increasing the surface
area. However, the passive technique involving so many ways like twisted tapes,
fins, ribs, rough surface, additives, extended surfaces, wire coil insert and
corrugations. Corrugated tubes are a type of enhanced heat transfer tool which has
become very interesting in the past few years.
Adopting a disturbance source in the flow direction is a preferred method for
the heat transfer enhancement. Setting up a disturbance promoter, which periodically
gags the flow along the streamwise to improve the heat exchange performance is a
common technique for the interrupting of the thermal boundary layer and mixing the
flow.
The main functions of corrugation are to promote the secondary recirculation
flow by inducing radial velocity components, mixing the flow layers and finally,
increasing the wet perimeter with holding the throat cross– section area constant,
6
which leads to increases the convective surface area. Therefore, it was extensively
used in modern heat exchangers and other heat transport devices. Especially in the
food industry, where the flow is should be at low Reynolds number. Hence, this kind
of tube would be helpful in the heat treatment process of juices flowing in tubes. It
will give good results with minimum requirements. Spiral corrugation increases heat
transfer enhancement due to the presence of secondary movements of the fluid
adjacent to the wall. Therefore, the emphasis was given to the use of corrugation in
heat transfer enhancement.
1.3. Research Hypothesis
The primary flow of fluid in tube with spiral corrugated surface extension
induced a secondary flow inside the corrugation. This secondary flow is most
probably of the vortex swirl flow type. The interaction of primary pipe flow and the
swirl secondary flow will produce a unique flow pattern. This unique flow pattern
which can be studied using high fidelity computational fluid dynamics (CFD)
techniques could be deduced in term of the heat transfer performance.
1.4. Research Questions
a) How corrugation height to diameter (e/d) affect heat transfer
enhancement?
b) What are the effects of corrugation pitch to diameter (p/d) on heat
transfer enhancement?
c) Does the number of corrugation (N) affect the heat transfer
enhancement?
7
d) What is the mechanism that are heat transfers enhancement in spirally
corrugated tubes?
e) Can this mechanism be studied effectively using CFD simulation?
1.5. Objectives
The main objective of this study to determine the optimum corrugation of
spirally corrugated tube with highest heat transfer enhancement and with a minimum
pressure drop penalty. In order to achieve this aim, the following sub objectives are
intended to be achieved:
a) To enhance the heat transfer by utilizing some modified spirally
corrugated tubes. This objective would be achieved by testing different
corrugation height to diameter e/d and corrugation pitch to diameter p/d
to produce swirl secondary flow and boundary layer, which means more
heat transfer
b) To simulate a double, triple and multiple corrugations starts of circular
profile by using commercial CFD software for the tube to increase heat
transfer and decrease pressure drop, while a single smooth tube of
certain specifications will be employed in experiments for validation
purposes.
c) To determine the thermal performance factor (η) for each tube. In
addition, to determine the number of start N effects on both heat transfer
and pressure drop.
8
1.6. Scope of Research
This study shall focus on the followings:
a) Laminar forced convective heat transfer of a Newtonian fluid flow in
spirally corrugated tubes will be considered.
b) Water will be taken as a working fluid and the flow will be assumed as
steady and incompressible. The fluid properties such as viscosity μ, heat
capacity cp and thermal conductivity k will be taken as a function of
temperature.
c) The investigation will be carried out numerically and experimentally
under a constant wall heat flux condition for 100<Re<1300 and for
various geometrical parameters in order to get wide range of database.
1.7. Significance and Contributions of this Study
The current study focused on laminar flow of water in corrugated tubes to
enhance the heat transfer rate because there is a lack in the experimental studies
concerning this subject in the literature as depicted in the next chapter in Section 2.4.
In addition, there are only three authors whom proposed correlations of
Nusselt number and friction factor for the laminar flow of water in annuli or fluted
tubes without taking the effect of severity index in to the account, and there is no
correlations regarding the corrugated tube.
9
1.8. Organization of the Thesis
This thesis consist of six chapters, each one deals with specific aspect.
Chapters (1-2) provide a general introduction and thesis headlines, in addition to the
deep and comprehensive review of the problem. While Chapters (3-5) provide the
detailed methodology and tools to investigate and solve the problem. Chapter 6
presents the outcomes and its interpretations.
Chapter 1 presents the general information about the problem and it is nature,
as well problem background. In addition, the motivation behind the need of the
current investigation and close scope on the problem with its limitations.
Chapter 2 involved the literature review and the research that conducted in
the past which are related to the current investigation research. It shows a
comprehensive and criticized review of about 95% of studies concerned with heat
transferred by corrugation. In addition it contains the summary of all the related
studies.
Chapter 3 depicts and describes the experimental methodology of the
research. Hence, it consists of the experimental rig description, experimental
procedure, experimental measurements and instrument calibration.
Chapter 4 explains the mathematical modelling and simulation steps. It’s also
explained in details the modeling of the problem besides the validation and
verification of the simulation process. The number and characteristics of the
numerically tested tubes were also depicted in this chapter. In addition to the mesh
process and convergence criteria.
10
Chapter 5 shows the results and their discussions. It also shows the effect of
different parameters that have significant effects on the results with reasonable
explanations. This chapter also presents the extracted correlations for the heat
transfer and friction factor.
183
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